|Publication number||US7226033 B2|
|Application number||US 10/862,790|
|Publication date||Jun 5, 2007|
|Filing date||Jun 7, 2004|
|Priority date||Jun 7, 2004|
|Also published as||US20050284093, WO2005121468A2, WO2005121468A3|
|Publication number||10862790, 862790, US 7226033 B2, US 7226033B2, US-B2-7226033, US7226033 B2, US7226033B2|
|Inventors||Brian R. Foucher, Anthony Collins|
|Original Assignee||Good Ideas, Llc|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (55), Non-Patent Citations (1), Referenced by (15), Classifications (33), Legal Events (3)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This invention is in the field of buildings, and in particular in the field of construction of buildings made at least in part of concrete.
The construction of buildings of concrete is typically accomplished by one of two methods. In a first method, forms are assembled at the construction site, typically from wood, in the shape of the desired object. The assembly of forms at the construction site is extremely labor intensive. Significant amounts of time are expended in the assembly of forms at the site, rendering construction schedules susceptible to delays from weather. The construction of forms corresponding accurately to plans requires careful measurement and alignment, which further increases the time involved in on-site processes.
In a second method, building elements of concrete, and generally of reinforced concrete, are constructed in a factory location. The use of a factory location overcomes some disadvantages, such as the need to properly align and construct forms at a construction site. However, transportation of concrete and reinforced concrete building elements is expensive, and is generally economical only for distances of, at most, a few hundred miles. The high cost derives from the fact that the concrete building elements are extremely heavy, often requiring specialized trucking equipment. The concrete building elements are also often not able to fit in standard truck beds, and require oversize load designations. Oversize load designations further increase the cost of transportation, by requiring special permits and accompanying vehicles to provide warnings.
It is an object of the invention to overcome the foregoing disadvantages of the prior art.
It is an advantage of the invention that the foregoing disadvantages of buildings and construction techniques of the prior art are overcome.
Additional objects and advantages of the invention will become evident from the detailed description which follows.
An apparatus of the invention comprises a wall or floor/ceiling section having two interior form surfaces, a shipping position in which the form surfaces are relatively in close proximity, and an assembled position in which the form surfaces are separated by a greater distance than in the shipping position, an interior space being defined between the form surfaces in the assembled position, the interior space being adapted to receive a flowable and setting material and to permit the flowable setting material to solidify in place, and hardware for alignment and attachment to adjacent sections.
In another aspect of the invention, a ceiling section for a structure has a substantially planar and continuous bottom form element, and components positioned on the bottom form element defining upright portions of a form, said components comprising adjustable components having a compact shipping orientation and an enlarged assembled orientation.
In another aspect of the invention, a structure segment has first and second wall sections, each of said wall sections having two opposing interior form surfaces, a shipping position in which the two interior form surfaces are relatively in close proximity, and an assembled position in which the two interior form surfaces are separated by a greater distance than in the shipping position, an interior space being defined between the interior form surfaces in the assembled position, and a first horizontal section rotatably attached to said first and second wall sections, said horizontal section comprising a substantially planar and continuous bottom form element and components positioned on said bottom form element defining upright portions of a form, said components comprising adjustable components having a compact shipping orientation and an enlarged assembled orientation.
In another aspect of the invention, a method of construction of a structure, comprising the steps of positioning at a construction location first and second wall sections, each of said wall sections having two opposing interior form surfaces, a shipping position in which the two interior form surfaces are relatively in close proximity, and an assembled position in which the two interior form surfaces are separated by a greater distance than in the shipping position, an interior space being defined between the interior form surfaces in the assembled position, and a first horizontal section rotatably attached to said first and second wall sections, said horizontal section comprising a substantially planar and continuous bottom form element and components positioned on said bottom form element defining upright portions of a form, said components comprising adjustable components having a compact shipping orientation and an enlarged assembled orientation; orienting said first and second wall sections and said first horizontal section in their assembled orientations; inserted a flowable structural material into said first and second wall sections and said first horizontal section, and permitting said flowable structural material to cure.
In another aspect of the invention, a method of construction of a structure includes positioning at a construction location, while in a compact shipping position, structure sections, the structure sections being positioned in an array; each of the structure sections has wall sections and a floor/ceiling sections; each of the wall sections has two opposing interior form surfaces, a shipping position in which the two interior form surfaces are relatively in close proximity, and an assembled position in which the two interior form surfaces are separated by a greater distance than in the shipping position, an interior space being defined between the interior form surfaces in the assembled position; each of the floor/ceiling sections has a substantially planar and continuous bottom form element and components positioned on the bottom form element defining upright portions of a form, the components including adjustable components having a compact shipping orientation and an enlarged assembled orientation. Each of the structure sections is moved from its compact shipping position to an assembled position. A flowable, setting material is introduced into the structure sections, and the material is permitted to set, whereby the array of structure sections defines a structure, supported by the set material.
In another aspect of the invention, a method of construction of a structure includes positioning at a construction location, while in a compact shipping position, structure sections in an array. The structure sections include floor/ceiling sections and post and beam forms. The floor/ceiling sections each include a substantially planar and continuous bottom form element and components positioned on the bottom form element defining upright portions of a form, the components including adjustable components having a compact shipping orientation and an enlarged assembled orientation. The post and beam forms have a compact shipping orientation and an enlarged assembled orientation. Each of the structure sections is moved from the compact shipping position to an assembled position, and a flowable, setting material is introduced into the structure sections, and the material is permitted to set, whereby the array of structure sections defines a structure, supported by the set material, and including posts and beams.
According to another aspect of the invention, an article for providing horizontal elements in a structure has transverse elongated rigid members, fabric attached to the members and defining transverse troughs and longitudinal fabric strips attached to the transverse members, the transverse members and the fabric strips defining a lattice.
A method of the invention includes, in one aspect, a method of construction of a structure. The method includes the steps of manufacture of sections for use as load-bearing floors and walls of a structure. The sections at least opposing interior form surfaces, which are generally planar and parallel. The separation between the opposing interior form surfaces is adjustable. The separation may be at a minimum in a folded orientation for shipment of the section. The separation may be at a greater distance in an assembly orientation. In an assembly orientation, the sections are adapted to receive a flowable, curable structural material, such as concrete, and to maintain the material in place until cured.
The sections may be constructed for self-alignment with adjacent sections. The sections may, in some embodiments, be rotatably attached to one another prior to assembly. The sections may have, in addition to surfaces, a structure to adjust the separation of the surfaces, and containing means for concrete, structural material, such as rebar, insulating material, and finish material, accommodation for utilities, wiring, ducts and pipes, and the like.
The adjustable separation between structural members 101, 102 may be achieved using any suitable mechanism. Means for providing adjustable separation may include rigid separators, such as bars, rotatably attached to structure members 101 102, or rods of fixed orientation but adjustable in length, such as a telescoping structure, or made up of multiple sections hingedly attached to one another.
In the depicted embodiment, grids 107 are the means for providing adjustable separation. Grids 107 have opposing longitudinal members 108, which are rigidly attached to structural members 101, 102. Transverse members 109 are rods rotatably attached at each end to longitudinal members 108. Transverse members 109 may be described as rotatably or hingedly attached at each end to structural members 101, 102.
Structural members 101, 102, may be of any material suitable in structural strength and weight in a generally planar form. As can be seen, structural members 101, 102 may have a ribbed or undulating configuration to increase structural strength. Materials may include sheet metal, a suitable plastic, or a composite. The members may also be of multiple layers built up of one or more materials.
Utility lines may also be provided within panel 100. Utility lines may include electrical wiring 115, water supply pipes 116, 117, wastewater pipes, fiber optic and wire cables for local computer networks, cable television and the like.
Finish features, such as exterior sheathing 110, and interior finish features, such as wallboard 111, may be applied on structural members 101, 102. Interior finish features illustrated in
Additional components to provide strength for the concrete or other flowing and setting material may be provided. An example of such strength-providing components is rebar in various shapes. By way of example, rebar 131 is shown. Rebar 131 is shown in the form of a grid, although this form is merely exemplary. Rebar may be supported on transverse members 109, so that the rebar is rotatable, as best seen in
Examples of the form of the concrete are shown at 132 and 146. A solid wall 132 results from filling the entire interior with concrete. A header with two vertical legs is obtained by providing appropriately shaped forms within the wall section 100.
Referring now to
Referring now to
Referring now to
Additional non-structural features may be included in floor/ceiling panel 800. In the illustrated example, radiant heating coils, ceiling drywall 820, and electrical wiring 822 are shown. Radiant heating coils 818 may be provided with modular attachments to a suitable source of power. Ceiling drywall 820 is provided with openings 824 for electrical wiring 822. Electrical wiring 822 may be provided for lighting, smoke detectors, communications, and other appropriate uses as desired.
Referring now to
Referring now to
Referring now to
Referring now to
The process of construction will now be explained. Construction is carried out typically on a foundation, such as exemplary foundation 1400 of
Referring now to
A window frame assembly 1830 is also illustrated in
Referring now to
The construction of a residential building is illustrated with reference to
The structure may take a wide variety of forms. The structure includes walls and a roof of a building suitable for use as a residence, storage, industrial, commercial, office and similar uses. The structure may be an open roof structure, such as a stadium. The completed structure refers to a structure which is suitable for use. In a typical structure, a structure is completed when an exterior surface is substantially complete, and when interior surfaces are completed.
Interior finish features include interior walls, of various materials, including drywall and wooden paneling, attached to the beams to define rooms. Interior wall surfaces may have finishes, such as paint or wallpaper. Interior wall surfaces may include openings for utilities, such as for electrical boxes for outlets and switches, openings for telephone, fiber optic and other types of communications wire and cable, and for water pipes for attachment of appliances.
Exterior finish surfaces will typically include a water-impermeable outer skin, of such materials as composites, aluminum, or treated or painted wood.
Wall section 100, which is exemplary, is for use in a structure, such as a residential building, such as a single family home, apartment building, motel or hotel. Wall section 100 is preferably assembled at a first location, which first location is distinct from the location of the placement of a structure of which wall section 100 is to be a part. For example wall section 100 may be intended for use in a structure to be placed on a foundation at a second location.
The first location may be a factory or other location for specialized assembly of structures and possibly other items. A variety of advantages may be obtained by use of factory assembly over assembly at a construction site. The factory may be located closer to sources of supply of inputs than the construction site. A factory offers better control over environmental conditions. Greater efficiencies in use of materials and in methods of fabrication and assembly of components may be obtained. The first location and second location may both be in the same country or economic area (e.g., the United States or the European Union). Shipment by ground transportation between the first and second location may be available. The first and second locations may be in different countries, but shipment by ground transportation, including truck and train, may be feasible. Truck transportation may include transport of trucks by ship for relatively short distances. The first and second locations may be on different continents, and wall section 100 may be transported by ship. Wall section 100 may be placed in a shipping container and shipped by one or more of water, rail and road.
External finish features may include any suitable weather resistant material, including aluminum panels, composite, wooden panels (clapboard), and other materials.
Optionally, cables and pipes may be incorporated in raceways. Electrical cables may include fixed sections and flexible end sections for adjustment and connection to electrical cables in adjacent wall panels. Similarly, water pipes may include rigid sections and flexible sections for attachment to pipes in adjacent sections. Pipes and wiring may be configured with flexible connectors, to connect to adjacent wall sections, and for final attachment to fixtures. Alternatively, pipes and wiring may be made of flexible materials.
Drywall 111 may be of conventional thickness and construction fixed to studs 104 in a conventional manner, such as by screws or nails. Drywall 111 is preferably not attached by removable fasteners. Drywall 111 may have a coating, such as a primer coat of conventional paint. Drywall 111 may be made of a single sheet of drywall, or may be made of several sheets positioned adjacent one another.
Depending on the needs of the particular application, wall section 100 may be the entire height of a story in a structure, or may be a fraction of the height. Multiple wall sections 100 may be joined by hinged joints to permit folding for transportation.
As an alternative to drywall, a ceiling may be of any material suitable for a ceiling surface of a structure.
Floor/ceiling sections may have utility components interior thereto. Such utility components may include cables, pipes, ducts and the like, and/or raceways for insertion of electrical and communications cabling, pipes and ducts, openings for electrical fixtures, openings for plumbing fixtures, raceways suitable for electrical cabling, communications cables, pipes and ducts. Floor/ceiling sections may have utility components, such as provisions for integrated utility functions, such as radiant floor heating.
The folded dimensions of structure segment 900 must be no greater than the dimensions available during transport. For example, if, as illustrated, four structure segments 900 are to be transported in a shipping container, the dimensions must be sufficiently small to permit insertion in the container. Typical shipping containers are 40 feet in length, and 7.5 feet in height and width (approximately). If structure segment 900 is to travel on a truck, the size is preferably sufficiently small that a standard roadgoing truck may be employed, without any need to designate the truck as carrying an oversize load. The maximum width of a load permitted without special oversize load permits varies, from about 8 feet, six inches, to about 10 feet or more.
Structure segment 900 may be of differing width depending on available transportation. For example, if transportation by road with oversize load designation is available, then, in the United States, the building segments may be significantly wider, such as up to 15 feet in width, and more than 15 feet in width, depending upon the route.
Structure segment 900 may be moved to an assembled position by a variety of techniques, including cables tied to floor/ceiling sections and lifted by a crane, a scissors lift, as explained below, a fork lift engaging lifting slots 808, a system of driven cables, and other techniques.
Any additional interior and exterior finish items may be attached at the first location. Such finish items may include trim and moldings, external features, such as decks and balconies, and internal features, such as cabinets and counters. Electrical outlets, switches and devices may be connected to wiring, and cables may be connected among sections. Other cables, pipes and fixtures may be connected. All of the foregoing connections are preferably fully reversible, making use of reversible electrical connectors for electrical connections, and other reversible connectors.
The structure may then be inspected for compliance with design specifications. Any errors in the manufacturing process that result in a failure of components to fit properly can be identified in such inspection and corrected. Replacement components can be obtained, or components altered for proper fit, or to correct other failures to comply with specifications. Inspections required to meet local building codes can be carried out. Code violations can be communicated by inspectors, and appropriate changes made to meet code can be made. If structures meet code, appropriate approvals or certificates can be issued at this time.
In addition to pouring of concrete, at the construction location, final finish work, including closing seams around connections and joints between building structures, and application of final surface treatments, such as painting, may be completed.
It will also be appreciated that the individual wall and floor/ceiling sections may be manufactured without provision for hinged connections. When the parts are assembled, they may be removably assembled together by reversible connections, such as various types of engineered locking devices, ties or screws. After testing, the connections are loosened, and the individual parts are packed for shipment. The parts may be packed in a container, similar to the discussion above. The parts may be loaded on suitable pallets or trailers, if desired. When the parts are delivered for final assembly, the parts are successively permanently attached to foundations and then to one another. The respective parts may be provided with features, such as mating protrusions and recesses, that will cause adjacent parts to be self-aligning. This variation still results in substantial cost savings upon assembly.
A variety of devices and methods may be employed for lifting and lowering components of the structure of the invention. In
Concrete and required equipment can be carried up via the elevator shaft as each floor is raised or by concrete pumping system or other suitable methods, thereby permitting completion of the next floor in each case, and avoiding the need for a crane. Multiple elevator shafts may be provided, and the size and shape of building sections may be varied to fit the selected design. The same technique may be employed using a crane as a replacement for or a supplement to an elevator.
Referring now to
A wide variety of variations in the materials and configurations of a structure and method of the invention are within the scope of the invention. For example, any suitable materials may be employed. Appropriate substitutes for concrete and metal structural components may be employed. The number of stories of a structure may be selected depending on the weight to be borne and the properties of the structural members, and structures of more than two stories are possible. The dimensions of sections of structures may be varied as appropriate to suit differing cargo containers and vehicles. The dimensions of structural components can be varied as appropriate to meet the load bearing, load carrying or unsupported span requirements as required by site specific conditions or code requirements. Finish surfaces, utilities, and the like, may be applied at a factory location, or may be added at the assembly location. Rotatable and sliding connections may be employed, or various self-aligning features, may be employed to assist with the proper alignment of sections that are not connected. The types of rotatable connections may vary. The methods used to unfold the parts may vary widely, including the use of fork lifts, cranes, driven pulleys, lifts, and other mechanisms.
Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.
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|U.S. Classification||249/44, 52/79.5, 249/47, 249/45, 52/284, 52/322, 52/319, 52/64, 249/192, 249/195, 52/270|
|International Classification||E04G11/00, E04G11/08, E04G11/06, E04C2/00, E04B1/16, E04B1/04, E04B1/00, E04B1/35, E04B2/86|
|Cooperative Classification||E04B1/04, E04B1/161, E04B2002/8688, E04B1/0023, E04B1/165, E04B1/3533, E04B2002/8694, E04B2/8635|
|European Classification||E04B1/04, E04B1/00C, E04B1/16D, E04B1/16A, E04B1/35E|
|Nov 1, 2004||AS||Assignment|
Owner name: GOOD IDEAS, LLC, VIRGIN ISLANDS, U.S.
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FOUCHER, BRIAN R.;COLLINS, ANTHONY;REEL/FRAME:015947/0207;SIGNING DATES FROM 20040926 TO 20041008
|Oct 29, 2010||FPAY||Fee payment|
Year of fee payment: 4
|Nov 5, 2014||FPAY||Fee payment|
Year of fee payment: 8